MAY 1, 2025

Waltco EM-Series Liftgate Safety: Verified Practices for Operators, Installers, and Fleet Managers

Liftgate safety is critical not only to protect personnel but also to ensure compliance with DOT regulations and to extend the life of your equipment. The Waltco EM-Series Owner’s Manual and Install Manual provide clear, enforceable safety guidance. This article distills that information into practical steps for operators, installers, and fleet managers.

• Documentation Resources from Waltco
• Operator Safety Guidelines
• Maintenance Safety Requirements
• Installation Safety Procedures
• Electrical and Hydraulic Safety
• DOT and Compliance Considerations
• Final Inspection for Safe Operation
• Conclusion: Verified Safety Starts With Verified Sources

Documentation Resources from Waltco

Information in this article is sourced from Waltco’s manuals and technical guides. Always refer to your specific liftgate’s manuals for complete procedures and serial number, model, and year-specific details.

Reference PDFs used:

• EM-Series Install Manual
• 80126403 REV 09.pdf (EM/EMTC Parts Manual)
• PB-WALTCO-EM-EN-US 231201.pdf (EM-Series Brochure)
• EM-Series Owners Manual

Operator Safety Guidelines

Operating a liftgate involves moving parts, hydraulic pressure, and heavy loads. Waltco provides a thorough list of safety rules every user must understand and follow before using the EM-Series liftgate.

→ Source: EM-Series Owner’s Manual, p. 4–5

Key Operator Safety Notes:

• Read and understand the Owner’s Manual, warning decals, and all safety instructions before operation.
• Do not operate the liftgate without full knowledge of how it functions.
• This liftgate is intended for cargo handling only. Personnel should only ride it if absolutely necessary, and only after reviewing the correct operation procedures.
• Maintain stable footing at all times, especially when riding with loads.
• Never ride the liftgate with unstable, stacked, or loose loads.
• Wheeled cargo must be secured to prevent rolling, and tall loads must be restrained from tipping.
• Load the platform as close to the vehicle and centered as possible to avoid uneven lifting or overloading.
• Never exceed the rated capacity of the liftgate. Check the load rating decal before use.
• Keep hands, feet, and bystanders clear of all moving parts and potential pinch points.
• If the liftgate makes unusual noises, vibrates, or raises/lowers unevenly, stop using it immediately.
• Do not operate the liftgate if there are signs of structural damage, such as cracked welds or bent supports.
• Do not attempt repairs unless you are qualified. For roadside issues, move the vehicle to a safe area away from traffic whenever possible.
• All safety covers, guards, and access doors must be in place during operation.
• Keep the area around and under the platform clear—never allow people to stand where a falling load could land.
• Properly store the platform in the stowed position during transit.
• Use a lock-out device or shut-off switch to prevent unauthorized operation.
• For gates with roller lifting chains, the chain must be replaced every 5 years or 15,000 cycles, whichever comes first.
• For liftgates used as loading ramps, only do so with reinforced platforms and support bars per model-specific guidance.
• If the gate includes a trailer hitch, never exceed its rated towing capacity or the vehicle's GVWR.
• Always follow the Maintenance Guide in the Owner’s Manual to keep the unit safe and compliant.

“Do not operate liftgate without a thorough knowledge and understanding of the operation of the liftgate.”
 — Owner’s Manual, p. 4

Maintenance Safety Requirements

Regular maintenance is essential—but it must be done safely and by qualified personnel. Improper repair or missed inspections can result in equipment failure or personal injury.

→ Source: EM-Series Owner’s Manual, pages 3, 4, 12, 16, 18
→ Install Manual, p. 37–38

Maintenance Safety Checklist Overview:

• Inspect structural welds, mounting brackets, and pivot pins regularly. If you observe cracks, bending, broken welds, or deformation, do not operate the liftgate until repairs are made.
• Check all bolts, nuts, and fasteners to ensure they are tight and properly torqued.
• Examine hydraulic hoses and fittings for leaks, wear, or chafing during each inspection cycle.
• Inspect the transit chain and verify it is securely connected to the liftgate’s chain lug before transit.
   → Transit chain requirements are critical for safe transport — Owner’s Manual, p. 16.
• Maintain all decals in legible condition, including operational instructions and safety warnings. Missing or damaged decals must be replaced immediately using only Waltco-authorized replacements.
• Never attempt liftgate repairs unless you are qualified. Repairs should only be done by trained personnel, preferably through an authorized Waltco distributor.
• If repair work must be performed roadside, move the vehicle away from traffic areas whenever possible. Always set up proper safety cones, markers, or hazard lights if work must be done near active roadways.
• When performing welding repairs, use appropriate PPE (personal protective equipment), including respiratory protection if welding produces hazardous fumes.
• Do not bypass or disable any safety devices, access covers, or guards. All protective components must be properly installed before returning the liftgate to service.

Failing to follow maintenance safety guidelines can lead to liftgate malfunction, cargo damage, serious injury, or loss of warranty coverage. Always use Waltco OEM parts and follow the manufacturer's maintenance schedule for maximum safety and performance.

Installation Safety Procedures

Installing a Waltco EM-Series liftgate requires proper preparation, clearance measurements, and lifting support. Cutting corners during this step can compromise vehicle compliance and long-term gate performance.

→ Source: EM-Series Install Manual, p. 3, 9–18

Installer Precautions:

• Do not install if the liftgate would prevent the vehicle from meeting state or federal compliance standards.
• Remove any obstructions from the rear sill, such as dock bumpers or hitch receivers.
• Maintain minimum tire clearance of 6" from the mount frame.
• Platform and mount must be fully supported with clamps or a forklift during installation.
• Welds must meet the 3/8" continuous specification, and torque all bolts to manufacturer specs.
• Never work under the platform or lift arms unless it is fully supported.
• Use proper PPE (gloves, eyewear, respiratory protection if welding).

“Failure to follow the installation instructions... may result in improper and unsafe operation of the liftgate.”
— Install Manual, p. 3

Electrical and Hydraulic Safety

Electrical and hydraulic systems in a liftgate can pose shock or pressure hazards if improperly handled. Waltco outlines clear requirements for safe wiring, pressure release, and system bleeding.

→ Source: EM-Series Install Manual, p. 21–28

Electrical Safety:

• Use dielectric grease on all terminals (pump, switch, battery).
• Protect wires with rubber grommets when passing through body panels.
• Mount the 150A circuit breaker directly to the battery, resting solidly to prevent vibration.
• Secure all cables away from heat sources, brake lines, and exhaust systems.

Hydraulic Safety:

• Never bleed or disconnect hoses without relieving pressure first.
• Use proper fluid types only: LiftLube™, LiftLube Arctic, or SAE 10W motor oil (above 32°F).
• Bleed both the raise and lower lines for power-down systems.
• If using dual cylinders (EMTC), bleed both cylinders individually.

“Do not attempt any repairs unless you are qualified to do so.”
— Owner’s Manual, p. 4

DOT and Compliance Considerations

The EM-Series includes features that must meet FMVSS and DOT regulations. Waltco offers guidance to ensure installations meet clearance and lighting standards.

→ Source: EM-Series Install Manual, p. 34–36, 51

DOT & Regulatory Compliance:

• Taillights must be visible and mounted per DOT regulations (suggested positions provided).
• Underride bumpers must not exceed 22" from the ground when in the stored position.
• Rubber dock bumpers, reflective lighting options, and walk ramp cutouts must be properly installed using provided instructions.

“Your installation of the vehicle taillights should meet all applicable regulations and requirements.”
— Install Manual, p. 34

Final Inspection for Safe Operation

Waltco includes a final inspection checklist to confirm the liftgate is installed, connected, and operating within safe parameters. This should be completed before the liftgate is ever put into service.

→ Source: EM-Series Install Manual, p. 38

Checklist Includes:

• Confirm pins, pivot bolts, and collars are properly secured.
• Test that the platform folds and unfolds smoothly.
• Verify proper operation of all control switches and shut-offs.
• Ensure the reservoir is full, system is bled, and all hoses are leak-free.
• All warning decals and manuals must be included and legible.

“Do not use liftgate if any of the above are not checked and verified.”
— Install Manual, p. 38

Conclusion: Verified Safety Starts With Verified Sources

Safety isn’t just a checklist item—it’s baked into the design and documentation of the Waltco EM-Series. Whether you’re installing, operating, or maintaining the liftgate, following only the verified manufacturer guidance ensures you stay compliant, reduce liability, and protect your people.

This article has pulled directly from Waltco’s manuals to give you actionable, inspection-ready safety practices. When in doubt, refer back to:

• The EM-Series Owner’s Manual
• The EM-Series Installation Manual
• Waltco’s official support team